Blow molded fencing system

ABSTRACT

A fence system including fence sections including singular blow-molded pickets that engage with fence rails using no additional parts and wherein the pickets show no external signs of functional engagement between the pickets and fence rails (e.g., pickets having substantially planar surfaces common to traditional wooden picket fence designs).

FIELD

This disclosure relates generally to fencing systems. More particularly,this disclosure relates to a picket fence system including singularblow-molded pickets.

BACKGROUND

The present disclosure relates to fence systems. Traditional wood picketfences have a desirable planar picket surface. When polymer or similarmaterials have been used to make construct similar fences due to, interalia, the lighter and more robust characteristics of such materials andmanufacturing techniques (e.g., extruding and/or blow-molding), aconsistent problem encountered in the art has been the inability toachieve a traditional planar picket surface using polymer-basedmaterials and related techniques. This problem is based at least in parton the external appearance of functional features in such polymer-basedfences wherein such appearance does not correspond with the traditionallook of similar fences made of wood. In particular, the pickets includedin traditional picket fence designs have substantially planar surfacesof various widths and thicknesses, and often a particular repeatingfeature on the top of each picket. Picket fences made using blow moldingtechniques and/or extrusion have not been able to reproduce such a lookand often require multiple parts per picket that must be attachedtogether.

What is needed therefore is a simplified picket fence system thatprovides a picket fence with a traditional picket fence look but whereinthe parts of the fence are minimal and are made using blow molding andextrusion technologies.

SUMMARY

The disclosure relates to a fencing system having a first singularblow-molded picket, a first substantially hollow rail, and a secondsubstantially hollow rail.

The first singular blow-molded picket includes a plurality ofinterference members defined along a first face of the first picket andat least one interference member defined along a second face of thefirst picket. The first picket is shaped according to a first predefinedblow-molding pattern. The first substantially hollow rail includes afirst aperture and a second aperture aligned on a common axis onopposing sides of the first rail and configured to tightly receive thefirst picket therethrough. A first interference member is locateddirectly adjacent a lower rim of the first aperture. The secondsubstantially hollow rail includes a third aperture and a fourthaperture aligned on a common axis on opposing sides of the second railand configured to tightly receive the first picket therethrough. Asecond interference member is located directly adjacent a lower rim ofthe third aperture. A third interference member is located directlyadjacent an upper rim of the second aperture or an internal upper rim ofthe fourth aperture.

In some examples, the first interference member is located directlyadjacent an internal lower rim of the first aperture, the secondinterference member is located directly adjacent an internal lower rimof the third aperture, and the third interference member is locateddirectly adjacent an internal upper rim of the second aperture or aninternal upper rim of the fourth aperture.

In other examples, the first interference member is defined along thefirst face of the first picket and the second interference member isdefined along the second face of the first picket. Additionally, afourth interference member is defined along the second face of the firstpicket, directly across from the first interference member, locateddirectly adjacent an internal lower rim of the first aperture. Also, afifth interference member is defined along the first face of the firstpicket, directly across from the second interference member, locateddirectly adjacent an internal lower rim of the third aperture.

In still other examples, the first interference member is defined alongthe first face of the first picket and the second interference member isdefined along the first face of the first picket. Additionally, a fourthinterference member is defined along the second face of the firstpicket, directly across from the first interference member, locateddirectly adjacent an internal lower rim of the first aperture. Lastly, afifth interference member is defined along the second face of the firstpicket, directly across from the second interference member, locateddirectly adjacent an internal lower rim of the third aperture.

In certain other examples, a second singular blow-molded picketincluding a second plurality of interference members is defined along afirst face of the second picket. Also, at least one interference memberis defined along a second face of the second picket, wherein the secondpicket is shaped according to a second predefined blow-molding pattern.Additionally, the first substantially hollow rail includes a fifthaperture and a sixth aperture that are aligned on a common axis onopposing sides of the first rail and are configured to tightly receivethe second picket. A fourth interference member is located directlyadjacent an internal lower rim of the fifth aperture. Also, the secondsubstantially hollow rail includes a seventh aperture and an eighthaperture that are aligned on a common axis on opposing sides of thesecond rail and are configured to tightly receive the second picket. Afifth interference member is located directly adjacent an internal lowerrim of the seventh aperture. Lastly, a sixth interference member islocated directly adjacent an internal upper rim of the sixth aperture oran internal upper rim of the eighth aperture.

In certain other examples, each of the interference members of theplurality of interference members includes a bulge. Each bulge includesat least one sloped edge.

In other embodiments, a sixth interference member is defined along thesecond face of the first picket, directly across from the thirdinterference member and is located directly adjacent an internal upperrim of the second aperture. Also, a seventh interference member isdefined along the second face of the first picket and is locateddirectly adjacent an internal upper rim of the fourth aperture. Lastly,an eighth interference member is defined along the first face of thefirst picket, directly across from the seventh interference member andis located directly adjacent an internal upper rim of the fourthaperture.

In some examples, the first pre-defined blow-molding pattern is the sameas the second pre-defined blow-molding pattern.

In some examples, the first pre-defined blow molding pattern has anaverage picket width of X and the second pre-defined blow moldingpattern has an average picket width of X×Y, wherein X and Y arevariables representing different numbers with each number provided inunits of length.

In some examples, the first pre-defined blow molding pattern has anaverage picket depth of X and the second pre-defined blow moldingpattern has an average picket depth of X×Y, wherein X and Y arevariables representing different numbers with each number provided inunits of length.

In some examples, the first pre-defined blow molding pattern has anaverage picket length of X and the second pre-defined blow moldingpattern has an average picket length of X×Y, wherein X and Y arevariables representing different numbers with each number provided inunits of length.

In a second set of examples, the disclosure relates to a kit of picketfence parts including a plurality of singular blow-molded pickets, afirst substantially hollow rail and a second substantially hollow rail.Each picket includes a plurality of interference members defined along afirst face of each picket. Also, each picket includes at least oneinterference member defined along a second face of each picket. At leasta first portion of the plurality of pickets are shaped according to afirst predefined blow-molding pattern. The first substantially hollowrail includes a first plurality of apertures spaced in a repeatingpattern along a first edge of the first rail and a second plurality ofapertures spaced in the repeating pattern along a second edge of thefirst rail. The second edge of the first rail is disposed opposite thefirst edge of the first rail such that the first rail includes repeatingfirst pairs of apertures. Each pair of apertures is configured fortightly receiving one of the plurality of pickets therethrough. Thesecond substantially hollow rail includes a third plurality of aperturesspaced in the repeating pattern along a first edge of the second railand a fourth plurality of apertures spaced in the repeating patternalong a second edge of the second rail. The second edge of the secondrail is disposed opposite the first edge of the second rail such thatthe second rail includes repeating second pairs of apertures. Each pairof apertures is configured for tightly receiving one of the plurality ofpickets therethrough.

Additionally, the pickets are configured to be fixedly attached to thefirst rail by sliding each of the plurality of pickets partially throughthe first pairs of apertures along the first rail such that at least oneinterference member per picket is located directly adjacent a respectivelower rim of a respective aperture of the first rail. Additionally, thepickets are configured to be fixedly attached to the second rail bysliding each of the plurality of pickets partially through the secondpairs of apertures along the second rail such that at least oneinterference member per picket is located directly adjacent a respectivelower rim of a respective aperture of the second rail. Sliding each ofthe plurality of pickets partially through the first pairs of aperturesalong the first rail and partially through the second pairs of aperturesalong the second rail also causes at least one interference member perpicket to be located directly adjacent a respective upper rim of arespective aperture of either the first rail or the second rail.

In some embodiments, the pickets are configured to be fixedly attachedto the first rail and the second rail by first sliding each of theplurality of pickets partially through the first pairs of aperturesalong the first rail such that at least one interference member perpicket is located directly adjacent a respective internal lower rim of arespective aperture of the first rail. Additionally, the pickets areconfigured to be fixedly attached to the first rail and the second railsuch that the pickets are provided load-bearing support along eachrespective lower rim. Lastly, the pickets are configured to be fixedlyattached to the first rail and the second rail by sliding each of theplurality of pickets partially through the second pairs of aperturesalong the second rail such that at least one interference member perpicket is located directly adjacent a respective internal lower rim of arespective aperture of the second rail, providing load bearing supportfor each respective picket along each respective lower rim.

In certain other embodiments, each picket of the plurality of singularblow-molded pickets includes a plurality of interference members definedalong a first face of each picket and at least one interference memberdefined along a second face of each picket. At least a second portion ofthe plurality of pickets are shaped according to a second predefinedblow-molding pattern.

BRIEF DESCRIPTION OF THE DRAWINGS

Further advantages of the disclosure are apparent by reference to thedetailed description in conjunction with the figures, wherein elementsare not to scale so as to more clearly show the details, wherein likereference numbers indicate like elements throughout the several views,and wherein:

FIG. 1A is a perspective view of a fence section according to a fencesystem described in the disclosure; FIG. 1B is an exploded view thereof;and FIG. 1C is a cross-sectional side view thereof.

FIGS. 2A-2C are perspective views of a rail component of the system ofFIGS. 1A-1C.

FIG. 3 is a perspective view of picket components of the system of FIGS.1A-1C.

FIGS. 4A-4C and 5A-5C show picket components of the system of FIGS.1A-1C.

FIG. 6A is a perspective view of a fence section according to anotherembodiment of the fence system described in the disclosure, and FIG. 6Bis an exploded view thereof.

FIG. 7A is a perspective view of a fence section according to yetanother embodiment of the fence system described in the disclosure, andFIG. 7B is an exploded view thereof.

FIG. 8A is a perspective view of a fence section according to a stillfurther embodiment of the fence system described in the disclosure; FIG.8B is a cross-sectional side view thereof; and FIGS. 8C and 8D areexploded views thereof

FIGS. 9A-9C are perspective views of a rail component of the system ofFIGS. 8A-8D.

FIGS. 10A-10C show a picket component of the system of FIGS. 8A-8D.

FIG. 11 shows an interference fit of a picket and a rail according tothe disclosure.

FIG. 12 shows relative dimensions of components of a picket and a railaccording to the disclosure.

FIG. 13 shows an exemplary partial cut-away side view of a picket andrails engaged with the picket.

FIG. 14 shows another exemplary partial cut-away side view of a picketand rails engaged with the picket.

FIG. 15 shows yet another exemplary partial cut-away side view of apicket and rails engaged with the picket.

FIG. 16 shows still another exemplary partial cut-away side view of apicket and rails engaged with the picket.

DETAILED DESCRIPTION

Referring to the FIGS. 1-16, the disclosure relates to a fencing systemincluding, for example, a fence section 10 including a plurality ofpickets 12, a first rail 14, and a second rail 16. Each of the pickets12 are formed as a single (or “singular”) piece by blow molding in asingle molding step and are, therefore, formed based on one or morepredefined blow-molding patterns. The first rail 14 is preferablysubstantially hollow and includes a plurality of first apertures 18along two opposing sides of the first rail 14, forming a pattern ofpairs of first apertures 18 along the first rail 14. Each pair of thefirst apertures 18 is configured to tightly receive one of the pickets12 therethrough. Similarly, the second rail 16 is also preferablysubstantially hollow and includes a plurality of second apertures 20along two opposing sides of the second rail 16, forming a pattern ofpairs of second apertures 20 along the second rail 16. Each pair of thesecond apertures 20 is configured to tightly receive one of the pickets12 therethrough.

With reference to FIGS. 13-16, each of the pickets 12 includes aplurality of interference members 22 defined thereon. At least two ofthe interference members (22A and 22C) for each picket are defined alonga first face 24 of each picket as well as at least one interferencemember (22B) defined along a second face 26 of each picket. For eachpicket, at least one interference member (22B) is located directlyadjacent a lower rim 28 of one of the first apertures 18, at least oneinterference member (22C) is located directly adjacent a lower rim 30 ofone of the second apertures 20, and at least one interference member(22A) is located directly adjacent either an upper rim 32 of one of thefirst apertures 18 or an upper rim 34 of one of the second apertures 20.

The interference member 22B is preferably located as shown in FIG. 13directly adjacent a lower rim 28 of one of the first apertures 18 froman internal position (internal of the first rail 14), thereby providingload bearing support function for the applicable picket. Similarly, theinterference member 22C is preferably located directly adjacent a lowerrim 30 of one of the second apertures 20 from an internal position(internal of the second rail 16), thereby providing load bearing supportfunction for the applicable picket. Preferably, each picket includes atleast four interference members 22 at every rail interface 36 as shownin FIG. 14 wherein the internal height “H” of each rail (14, 16) isapproximately the same as the distance “D” between outer edges 38 of theinterference members 22 located on the same face of a picket between arail.

FIG. 15 shows an example of a picket that includes three interferencemembers 22 per rail interface 36. FIG. 16 shows an example of a picketwherein some of the interference members 22 are located at locationsexternal from the first rail 14 and the second rail 16. However,internal location of interference members is preferred so as to preservethe look of a traditional picket fence with pickets made of wood orotherwise having substantially smooth and flat, panel-like exteriorsurfaces.

As shown by comparing FIG. 1A, FIG. 6C, FIG. 7A, and FIG. 8A, the styleof picket can vary, which, in turn, can vary the size and/or shape ofapertures in the various rail designs to accommodate for the differentsizes of the variously styled pickets. FIG. 1A through FIG. 3 show anexample of a picket fence section 40 wherein the style of picket variesaccording to a repeating pattern along the fence section 40. Because thestyle and size of picket varies according to a particular pattern, thesize of the respective apertures 18 in the first rail 14 and the size ofthe respective apertures 20 in the second rail 16 also vary accordinglyas shown, for example, in FIGS. 2A-2C.

FIGS. 6A-6B show another example of a fence section 42 including pickets44 all made from a first predefined blow-molding pattern along with anupper rail 46 and a lower rail 48, wherein both rails include apertures50 configured for receiving the pickets 44. FIGS. 7A-7B show yet anotherexample of a fence section 52 including pickets 54 made from a secondpredefined blow-molding pattern along with an upper rail 56 and a lowerrail 58, wherein both rails include apertures 60 configured forreceiving the pickets 54. A plurality of interference members 62 aredefined along widthwise surfaces 64 of the pickets 54 in this example.FIGS. 8A-10C show a third example of a fence section 66 includingpickets 68 all made from a third predefined blow-molding pattern alongwith an upper rail 70 and a lower rail 72, wherein both rails includeapertures 74 configured for receiving the pickets 68. A plurality ofinterference members 76 are defined along the depthwise surfaces 78 ofthe pickets 68 in this example.

The size of various components of the fence system described herein canvary based on various factors including, for example, customer need,although traditional fence picket heights, widths, and lengths are oftenpreferable. The plurality of fence pickets and associated rails arepreferably made of polyvinyl chloride (PVC), high density polyethylene,polypropylene or other similar polymer, copolymer, and/or combinationsthereof The rails are preferably made using an extrusion process. Fencesare preferably formed in sections (e.g., the fence section 10 shown inFIG. 1A) prior to shipment to dealers or customers. However, kits ofpicket fence components are also contemplated wherein the fencecomponents are shipped unattached. FIG. 8C shows an example of a fencekit 80 including the plurality of pickets 68, the upper rail 70, and thelower rail 72 used to form the fence section 66 shown in FIG. 8A. Endposts may be included in fence kits wherein the upper rail 70 and thelower rail 72 are attached to the end posts in any manner known toperson having ordinary skill in the art.

The previously described examples of the present disclosure have manyadvantages, including providing traditionally styled picket fencesections made from recyclable and/or recycled material, the whole ofwhich is lighter than wood and more impervious to the elements thantraditional wood picket fences. Another advantage is the traditionalappearance of painted wooden picket fence pickets with substantiallyplanar surfaces with little or no functional features appearing on theoutside surfaces of the various parts of each fence section.

The foregoing descriptions of preferred embodiments for this disclosurehave been presented for purposes of illustration and description. Theyare not intended to be exhaustive or to limit the disclosure to theprecise form disclosed. Obvious modifications or variations are possiblein light of the above teachings. The embodiments are chosen anddescribed in an effort to provide the best illustrations of theprinciples of the disclosure and its practical application, and tothereby enable one of ordinary skill in the art to utilize thedisclosure in various embodiments and with various modifications as aresuited to the particular use contemplated. All such modifications andvariations are within the scope of the disclosure as determined by theappended claims when interpreted in accordance with the breadth to whichthey are fairly, legally, and equitably entitled.

1. A fencing system, comprising: a. a first singular blow-molded picketincluding a plurality of interference members defined along a first faceof the first picket and at least one interference member defined along asecond face of the first picket, wherein the first picket is shapedaccording to a first predefined blow-molding pattern; and b. a firstsubstantially hollow rail including a first aperture and a secondaperture aligned on a common axis on opposing sides of the first railand configured to tightly receive the first picket therethrough, whereina first interference member is located directly adjacent a lower rim ofthe first aperture; c. a second substantially hollow rail including athird aperture and a fourth aperture aligned on a common axis onopposing sides of the second rail and configured to tightly receive thefirst picket therethrough, wherein a second interference member islocated directly adjacent a lower rim of the third aperture; and d. athird interference member located directly adjacent an upper rim of thesecond aperture or an internal upper rim of the fourth aperture.
 2. Thesystem of claim 1, comprising: a. the first substantially hollow railincluding a first aperture and a second aperture aligned on a commonaxis on opposing sides of the first rail and configured to tightlyreceive the first picket therethrough, wherein a first interferencemember is located directly adjacent an internal lower rim of the firstaperture; b. the second substantially hollow rail including a thirdaperture and a fourth aperture aligned on a common axis on opposingsides of the second rail and configured to tightly receive the firstpicket therethrough, wherein a second interference member is locateddirectly adjacent an internal lower rim of the third aperture; and c.the third interference member located directly adjacent a locationselected from the group consisting of an internal upper rim of thesecond aperture and an internal upper rim of the fourth aperture.
 3. Thesystem of claim 2, comprising: a. the first interference member definedalong the first face of the first picket and the second interferencemember defined along the second face of the first picket; b. a fourthinterference member defined along the second face of the first picket,directly across from the first interference member, located directlyadjacent an internal lower rim of the first aperture; and c. a fifthinterference member defined along the first face of the first picket,directly across from the second interference member, located directlyadjacent an internal lower rim of the third aperture.
 4. The system ofclaim 2, comprising: a. the first interference member defined along thefirst face of the first picket and the second interference memberdefined along the first face of the first picket; b. a fourthinterference member defined along the second face of the first picket,directly across from the first interference member, located directlyadjacent an internal lower rim of the first aperture; and c. a fifthinterference member defined along the second face of the first picket,directly across from the second interference member, located directlyadjacent an internal lower rim of the third aperture.
 5. The system ofclaim 2, comprising: a. a second singular blow-molded picket including asecond plurality of interference members defined along a first face ofthe second picket and at least one interference member defined along asecond face of the second picket, wherein the second picket is shapedaccording to a second predefined blow-molding pattern; b. the firstsubstantially hollow rail including a fifth aperture and a sixthaperture aligned on a common axis on opposing sides of the first railand configured to tightly receive the second picket therethrough,wherein a fourth interference member is located directly adjacent aninternal lower rim of the fifth aperture; c. the second substantiallyhollow rail including a seventh aperture and an eighth aperture alignedon a common axis on opposing sides of the second rail and configured totightly receive the second picket therethrough, wherein a fifthinterference member is located directly adjacent an internal lower rimof the seventh aperture; and d. a sixth interference member locateddirectly adjacent a location selected from the group consisting of aninternal upper rim of the sixth aperture and an internal upper rim ofthe eighth aperture.
 6. The system of claim 2, wherein each of theinterference members of the plurality of interference members comprisesa bulge, each bulge including at least one sloped edge.
 7. The system ofclaim 3, comprising: a. a sixth interference member defined along thesecond face of the first picket, directly across from the thirdinterference member and located directly adjacent an internal upper rimof the second aperture; b. a seventh interference member defined alongthe second face of the first picket, located directly adjacent aninternal upper rim of the fourth aperture; and c. an eighth interferencemember defined along the first face of the first picket, directly acrossfrom the seventh interference member and located directly adjacent aninternal upper rim of the fourth aperture.
 8. The system of claim 5wherein the first pre-defined blow molding pattern is the same as thesecond pre-defined blow molding pattern.
 9. The system of claim 5,wherein the first pre-defined blow molding pattern comprises an averagepicket width of X and wherein the second pre-defined blow moldingpattern comprises an average picket width of X×Y, wherein X and Y arevariables representing different numbers with each number provided inunits of length.
 10. The system of claim 5, wherein the firstpre-defined blow molding pattern comprises an average picket depth of Xand wherein the second pre-defined blow molding pattern comprises anaverage picket depth of X×Y, wherein X and Y are variables representingdifferent numbers with each number provided in units of length.
 11. Thesystem of claim 5, wherein the first pre-defined blow molding patterncomprises an average picket length of X and wherein the secondpre-defined blow molding pattern comprises an average picket length ofX×Y, wherein X and Y are variables representing different numbers witheach number provided in units of length.
 12. A kit of picket fenceparts, comprising: a. a plurality of singular blow-molded pickets, eachpicket including a plurality of interference members defined along afirst face of each picket and at least one interference member definedalong a second face of each picket, wherein at least a first portion ofthe plurality of pickets are shaped according to a first predefinedblow-molding pattern; b. a first substantially hollow rail including afirst plurality of apertures spaced in a repeating pattern along a firstedge of the first rail and a second plurality of apertures spaced in therepeating pattern along a second edge of the first rail, wherein thesecond edge of the first rail is disposed opposite the first edge of thefirst rail such that the first rail includes repeating first pairs ofapertures, each pair of apertures configured for tightly receiving oneof the plurality of pickets therethrough; c. a second substantiallyhollow rail including a third plurality of apertures spaced in therepeating pattern along a first edge of the second rail and a fourthplurality of apertures spaced in the repeating pattern along a secondedge of the second rail, wherein the second edge of the second rail isdisposed opposite the first edge of the second rail such that the secondrail includes repeating second pairs of apertures, each pair ofapertures configured for tightly receiving one of the plurality ofpickets therethrough; wherein the pickets are configured to be fixedlyattached to the first rail and the second rail by sliding each of theplurality of pickets partially through the first pairs of aperturesalong the first rail such that at least one interference member perpicket is located directly adjacent a respective lower rim of arespective aperture of the first rail; and sliding each of the pluralityof pickets partially through the second pairs of apertures along thesecond rail such that at least one interference member per picket islocated directly adjacent a respective lower rim of a respectiveaperture of the second rail; wherein the sliding each of the pluralityof pickets partially through the first pairs of apertures along thefirst rail and partially through the second pairs of apertures along thesecond rail also causes at least one interference member per picket tobe located directly adjacent a respective upper rim of a respectiveaperture of either the first rail or the second rail.
 13. The kit ofpicket fence parts of claim 12 wherein the pickets are configured to befixedly attached to the first rail and the second rail by sliding eachof the plurality of pickets partially through the first pairs ofapertures along the first rail such that at least one interferencemember per picket is located directly adjacent a respective internallower rim of a respective aperture of the first rail, providing loadbearing support for each respective picket along each respective lowerrim; and sliding each of the plurality of pickets partially through thesecond pairs of apertures along the second rail such that at least oneinterference member per picket is located directly adjacent a respectiveinternal lower rim of a respective aperture of the second rail,providing load bearing support for each respective picket along eachrespective lower rim.
 14. The kit of picket fence parts of claim 12,further comprising: the plurality of singular blow-molded pickets, eachpicket including a plurality of interference members defined along afirst face of each picket and at least one interference member definedalong a second face of each picket, wherein at least a second portion ofthe plurality of pickets are shaped according to a second predefinedblow-molding pattern.